Craftsman 137211940 User Manual COMPOUND MITER SAW Manuals And Guides L0811588
CRAFTSMAN Miter Saw Manual L0811588 CRAFTSMAN Miter Saw Owner's Manual, CRAFTSMAN Miter Saw installation guides
User Manual: Craftsman 137211940 137211940 CRAFTSMAN COMPOUND MITER SAW - Manuals and Guides View the owners manual for your CRAFTSMAN COMPOUND MITER SAW #137211940. Home:Tool Parts:Craftsman Parts:Craftsman COMPOUND MITER SAW Manual
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Operator's Manual CRRFrSr4RH° 7-1/4 in. SLiDiNG COMPOUND MITER SAW WiTH LASER TRAC ® Model No. 137.211940 C US CAUTION: • Safety Instructions Before using this Miter Saw, read this manual and follow all its Safety Rules and Operating Instructions • Installation • Operation • Maintenance • Parts List Customer Help Line For Technical Support 1-800-843-1682 Sears Parts & Repair Center 1-800-488-1222 Sears, Roebuck and Co., Hoffman Estates, IL 60179 USA Visit our Craftsman website: www.sears.com/craftsman Part No. 137211940001 Printed in China SECTION PAGE Warranty......................................................................................... 2 ProductSpecifications ....................................................................3 Symbols .......................................................................................... 4 PowerToolSafety.......................................................................... 5 Compound MiterSawSafety..........................................................7 ElectricalRequirements andSafety .................................................. 9 Accessories andAttachments ........................................................11 ToolsNeededforAssembly ............................................................12 CartonContents............................................................................. 13 KnowYourSlidingCompound MiterSaw......................................... 14 GlossaryofTerms.......................................................................... 15 Assembly andAdjustments .............................................................17 Operation....................................................................................... 26 Maintenance ................................................................................... 37 Troubleshooting Guide...................................................................39 PartsList........................................................................................ 41 CRAFTSMAN ONE YEAR FULL WARRANTY If this Craftsman tool fails due to a defect in material or workmanship within one year from the date of purchase, call 1-800-4-MY-HOME ® to arrange for free repair (or replacement if repair proves impossible). This warranty applies for only 90 days from the date of purchase if this product is ever used for commercial or rental purposes. This warranty does not include expendable parts, such as lamps, batteries, bits or blades. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. Sears, Roebuck and Co., Hoffman Estates, IL 60179 WARNING ] Some dust created by using power tools contains chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Some examples of these chemicals are: o Lead from lead-based paints o Crystalline silica from bricks, cement and other masonry products • Arsenic and chromium from chemically treated lumber Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals, work in a well ventilated area and work with approved safety equipment such as dust masks that are specially designed to filter out microscopic particles. MOTOR Power Source ..................................................................... Speed ................................................................................. Brake .................................................................................. Double Insulated ................................................................. 9Amp, 120V AC, 60Hz 5000 RPM (No load) Electric Yes BLADE SIZE Diameter .............................................................................. Arbor size ............................................................................ 7-1/4 in. 5/8 in. ROTATING TABLE: Diameter ............................................................................ 9-1/32 in. Miter Detent Stops ............................................................ 0, 15, 22.5, 31.6, 45°R & L Bevel Positive Stops ......................................................... 0, 45° L CUTTING CAPACITY: Crosscut ............................................................................ Miter 45 ° R & L ................................................................... Bevel 45 ° L ......................................................................... 45 ° Miter and 45 ° Bevel ..................................................... 2 in. x 8 in. 2 in. x 6 in. 1-1/2 in. x 8 in. 1-1/2 in. x 6 in. i_J_ WARNING] To avoid electrical hazards, fire hazards or damage to the tool, use proper circuit protection. This tool is wired at the factory for 110=120 Volt operation, it must be connected to a 110=120 Volt / 15 Ampere time delay fuse or circuit breaker. To avoid shock or fire, replace power cord immediately if it is worn, cut or damaged in any way. Before using your tool, it is critical that you read and understand these safety rules. Failure to follow these rules could result in serious injury to you or damage to the tool. WARNINGiCONS Your power tool and its Operator's Manual may contain "WARNING iCONS" (a picture symbol intended to alert you to, and/or instruct you how to avoid, a potentially hazardous condition). Understanding and heeding these symbols will help you operate your tool better and safer. Shown below are some of the symbols you may see. SAFETY ALERT: Precautions that involve your safety. ® PROHiBiTiON WEAR EYE PROTECTION: glasses with side shields. Always wear safety goggles or safety READ AND UNDERSTAND OPERATOR'S MANUAL: To reduce the risk of injury, user and all bystanders must read and understand operator's manual before using this product. KEEP HANDS AWAY FROM BLADE: Failure to keep your hands away from the blade will result in serious 3ersonal injury. SUPPORT AND CLAMP WORK [,_, DANGER] DANGER: indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING: indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. GENERALSAFETY 8. Safety is a combination of common sense, staying alert and knowing how to use your power tool. DO NOT FORCE THE TOOL. It will do the job better and safer at the rate for which it was designed. 9. USE THE RIGHT TOOL. Do not force the tool or an attachment to do a job for which it was not designed. iNSTRUCTiONS BEFORE USING THIS POWER TOOL CAUTION To avoid mistakes that could cause serious injury, do not plug the tool in until you have read and understood the following. . . . . . . . READ and become familiar with the entire Operator's Manual. LEARN the tool's application, limitations and possible hazards. KEEP GUARDS iN PLACE and in working order. REMOVE ADJUSTING KEYS AND WRENCHES. Form the habit of checking to see that keys and adjusting wrenches are removed from the tool before turning ON. KEEP WORK AREA CLEAN. Cluttered areas and benches invite accidents. DO NOT USE iN DANGEROUS ENVIRONMENTS. Do not use power tools in damp locations, or expose them to rain or snow. Keep work area well lit. KEEP CHILDREN AWAY. All visitors and bystanders should be kept a safe distance from work area. MAKE WORKSHOP CHILD PROOF with padlocks, master switches or by removing starter keys. 10. USE PROPER EXTENSION CORDS. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will result in a drop in line voltage and in loss of power which will cause the tool to overheat. The table on page 10 shows the correct size to use depending on cord length and nameplate ampere rating. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord. 11. WEAR PROPER APPAREL. Do not wear loose clothing, gloves, neckties, rings, bracelets or other jewelry which may get caught in moving parts. Nonslip footwear is recommended. Wear protective hair covering to contain long hair. 12. PROTECTION. Any power ALWAYS WEAR EYE tool can throw foreign objects into the eyes and could cause permanent eye damage. ALWAYS wear Safety Goggles (not glasses) that comply with ANSI Safety standard Z87.1. Everyday eyeglasses have only impact-resistant lenses. They ARE NOT safety glasses. Safety Goggles are available at sears. O NOTE:Glassesorgogglesnotin compliance with ANSI Z87.1 could seriously injure you when they break. and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced. 13. WEAR A FACE MASK OR DUST MASK. Sawing operation produces dust. 20. NEVER LEAVE THE TOOL RUNNING UNATTENDED. TURN THE POWER "OFF". Do not walk away from a running tool until the blade comes to a complete stop and the tool is unplugged from the power source. 14. SECURE WORK. Use clamps or a vise to hold work when practical. It is safer than using your hand and it frees both hands to operate the tool. 15. DISCONNECT TOOLS FROM POWER SOURCE before servicing, and when changing accessories such as blades, bits and cutters. 16. REDUCE THE RiSK OF UNINTENTIONAL STARTING. Make sure switch is in the OFF position before plugging the tool in. 17. USE RECOMMENDED ACCESSORIES. Consult this Operator's Manual for recommended accessories. The use of improper accessories may cause risk of injury to yourself or others. 18. NEVER STAND ON THE TOOL. Serious injury could occur if the tool is tipped or if the cutting tool is unintentionally contacted. 19. CHECK FOR DAMAGED PARTS. Before further use of the tool, a guard or other part that is damaged should be carefully checked to determine that it will operate properly and perform its intended function - check for alignment of moving parts, binding of moving parts, breakage of parts, mounting 21. DO NOT OVERREACH. Keep proper footing and balance at all times. 22. MAINTAIN TOOLS WiTH CARE. Keep tools sharp and clean for best and safest performance. Follow instructions for lubricating and changing accessories. 23. WARNING: Dust generated from certain materials can be hazardous to your health. Always operate saw in well-ventilated area and provide for proper dust removal. 24.IA, DANGER ] People with electronic devices, such as pacemakers, should consult their physician(s) before using this product. Operation of electrical equipment in close proximity to a heart pacemaker could cause interference or failure of the pacemaker. SPECiFiC SAFETY iNSTRUCTiONS FOR THiS COMPOUND MITER SAW . . . . DO NOT operate the miter saw until it is completely assembled and installed according to these instructions. iF YOU ARE NOT thoroughly familiar with the operation of miter saws, seek guidance from your supervisor, instructor or other qualified person. ALWAYS hold the work firmly against the fence and table. DO NOT perform any operation free hand (use clamp wherever possible). KEEP HANDS out of the path of the saw blade. If the workpiece you are cutting would cause your hands to be within 6-3/4 in. of the saw blade, the workpiece should be clamped in place before making the cut. 5. BE SURE the blade is sharp, runs freely and is free of vibration. 6. ALLOW the motor to come up to full speed before starting a cut. 7. KEEP THE MOTOR AiR SLOTS CLEAN and free of chips or dust. 8. ALWAYS MAKE SURE all handles are tight before cutting, even if the table is positioned in one of the positive stops. 9. BE SURE both the blade and the collar are clean and the arbor bolt is tightened securely. 10. USE only blade collars specified for your saw. 11. NEVER use blades larger in diameter than 7-1/4 inches. 12. NEVER apply lubricants to the blade when it is running. 13. ALWAYS check the blade for cracks or damage before operation. Replace a cracked or damaged blade immediately. 14. NEVER use blades recommended for operation at less than 5000 RPM. 15. ALWAYS keep the blade guards in place and use at all times. 16. NEVER reach around the saw blade. 17. MAKE SURE the blade is not contacting the workpiece before the switch is turned ON. 18. iMPORTANT: After completing the cut, release the trigger and wait for the blade to stop before returning the saw to the raised position. 19. MAKE SURE the blade has come to a complete stop before removing or securing the workpiece, changing the workpiece angle or changing the angle of the blade. 20. NEVER cut metals or masonry products with this tool. This miter saw is designed for use on wood and wood-like products. 21.NEVERcutsmallpieces.If the workpiece beingcutwouldcause yourhandorfingerstobewithin 6-3/4in.ofthesawbladethe workpiece is toosmall. 22.PROVIDE adequate supporttothe sidesofthesawtableforlongwork pieces. 23.NEVERusethemitersawinan areawithflammable liquidsor gases. 24.NEVERusesolventstoclean plasticparts.Solventscould possiblydissolveor otherwise damagethematerial. 25.SHUTOFFthepowerbefore servicingoradjustingthetool. 26.DISCONNECT thesawfrom thepowersourceandcleanthe machinewhenfinishedusing. 27.MAKESUREtheworkareais cleanbeforeleavingthe machine. 28.SHOULD anypartofyourmitersaw bemissing,damaged, orfail inany way,oranyelectricalcomponent failtoperformproperly,lockthe switchandremovetheplugfrom thepowersupplyoutlet.Replace missing,damaged, or failedparts beforeresuming operation. POWERSUPPLYANDMOTOR SPECiFiCATiONS TheACmotorusedinthissawis a universal,nonreversible type. See"MOTOR" inthe"PRODUCT SPECIFICATIONS" sectiononpage3. [,,d_ WARNING] To avoid electrical hazards, fire hazards, or damage to the tool, use proper circuit protection. Your saw is wired at the factory for 120 V operation. Connect to a 120 V, 9A circuit and use a 9 A time delay fuse or circuit breaker. To avoid shock or fire, if power cord is worn or cut, or damaged in any way, have it replaced immediately. DOUBLE iNSULATED [] The power tool is double insulated to provide a double thickness of insulation between you and tool's electrical system. All exposed metal parts are isolated from the internal metal motor components with protecting insulation. Replacement parts - When servicing, use only identical replacement parts. Polarized plugs - This saw has a plug that looks like the one shown below: To reduce the risk of electrical shock, this saw has a polarized plug (one blade is wider than the other). This plug will fit in a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit, contact a qualified electrician to install the proper outlet. Do not change the plug in any way. I,A WARNING J Double insulation does not take the place of normal safety precautions when operating this tool. To avoid electrocution: 1. Use only identical replacement parts when servicing a tool with double insulation. Servicing should be performed by a qualified technician. 2. Do not use power tools in wet or damp locations or expose them to rain or snow. MOTOR SAFETY PROTECTION iMPORTANT To avoid motor damage, the motor should be blown out or vacuumed frequently to keep sawdust from interfering with the motor ventilation. 1. Connect this saw to a 120 V circuit. This circuit must not be less than a #18 wire with a 9 A time lag fuse. NOTE: When using an extension cord on a circuit with a #18 wire, the extension cord must not exceed 25 feet in length. 2. If the motor will not start, release the trigger switch immediately. UNPLUG THE SAW. Check the saw blade to make sure it turns freely. If the blade is free, try to start the saw again. If the motor still does not start, refer to the TROUBLESHOOTING GUIDE. 3. If the tool suddenly stalls while cutting wood, release the trigger switch, unplug the tool and free the blade from the wood. The saw may nowbestartedandthecutfinished. excessiveheatanddamporwetareas. 4. FUSESmay"blow"or circuit Use a separate electrical circuit for breakersmaytripfrequentlyif: your tools. This circuit must not be a. MOTORisoverloaded less than a #18 wire with a 9 A time lag overloading canoccurifyoufeed fuse. NOTE: When using an extension cord on a circuit with a #18 wire, the too rapidlyor maketoo many extension cord must not exceed 25 feet start/stops ina shorttime. b. LINEVOLTAGEis more in length. Before connecting the tool to than10%aboveor belowthe the power line, make sure the switch nameplate voltagerating.For is in the OFF position and the electric heavyloads,thevoltageat motor current is rated the same as the current terminalsmustequalthevoltage stamped on the motor nameplate, specifiedonthenameplate. running at a lower voltage will damage c. IMPROPER or dullsawblades the motor. areused. 5. Mostmotortroublesmaybetraced • O" O e'| to looseor incorrectconnections, (When using 120 volts only) overload,lowvoltageor inadequate Ampere Rating Total tength of Cord powersupplywiring.Alwayscheck More Than Not More Than 25ft. 50ft. 100ft. 150ft. 0 6 18 16 16 14 theconnections, theloadand supplycircuitif themotordoesn't 12 16 16 14 12 runwell.Checkminimumgaugefor 1012 16 14 12 Not Recommended the lengthofcordyouareusingon thechartbelow. GUIDELINES FOREXTENSION CORDS Usea properextension cord.Make sureyourextension cordis ingood condition.Whenusinganextension cord,besureto useoneheavyenough tocarrythecurrentyourproductwill draw.An undersized cordwillcause a dropinlinevoltage,resultingin lossofpowerandoverheating. The tablebelowshowsthecorrectsize to usedepending oncordlengthand nameplate ampererating.If indoubt, usethenextheaviergauge.The smallerthegaugenumber,theheavier thecord. Besureyourextensioncord is properlywiredandingoodcondition. Alwaysreplacea damaged extension cordorhaveit repairedbya qualified personbeforeusingit. Protectyour extensioncordsfromsharpobjects, CAUTION: in all cases make certain the receptacle in question is properly grounded, if you are not sure, have a certified electrician check the receptacle. RECOMMENDED ACCESSORIES i,_ WARNING] o o o Use only accessories recommended for this miter saw. Follow instructions that accompany accessories. Use of improper accessories may cause hazards. The use of any cutting tool except 7-1/4 in. saw blades which meet the requirements under recommended accessories is prohibited. Do not use accessories such as shaper cutters or dado sets. Ferrous metal cutting and the use of abrasive wheels is prohibited. Do not attempt to modify this tool or create accessories not recommended for use with this tool. Any such alteration or modification is misuse and could result in a hazardous condition leading to possible serious injury. ACCESSORIES Visit your Sears Hardware Department or see the Sears Power and Hand Tool Catalog to purchase recommended accessories for this power tool. i,A WARNING] o o To avoid the risk of personal injury, do not modify this power tool or use accessories not recommended by Sears. Read warnings and conditions on your CARBIDE TIPPED SAW BLADE. Do not operate the saw without the proper saw blade guard in place. Carbide is a very hard but brittle material. Care should be taken while mounting, using, and storing carbide tipped blades to prevent accidental damage. Slight shocks, such as striking the tip while handling, can seriously damage the blade. Foreign objects in the workpiece, such as wire or nails, can also cause tips to crack or break off. Before using, always visually examine the blade and tips for bent blade, cracks, breakage, missing or loose tips, or other damage. Do not use if damage is suspected. Failure to heed safety instructions and warnings can result in serious bodily injury. Supplied Not supplied Blade Wrench Adjustable Wrench 6mm Hex Wrench Phillips Screwdriver Slotted Screwdriver Combination Square COMBINATION SQUARE MUST BE TRUE Should not gap or overlap when square is flipped over (see dotted figure). Straight edge or a 3/4 in. board, this edge must be perfectly straight. Draw light line on board along this edge. Should not gap or overlap when square flipped over (see dotted figure). 12 UNPACKING YOUR MITER SAW {_ WARNING] To avoid injury from unexpected starting or electrical shock, do not plug the power cord into a source of power during unpacking and assembly. This cord must remain unplugged whenever you are working on the saw. 1. 2. Remove the miter saw from the carton. IMPORTANT: Do not lift miter saw by the trigger switch handle, it may cause misalignment. Only lift machine by the base hand holds. Place the saw on a secure stationary work surface. 3. Separate all parts from the packing material. Check each one with the illustration to make certain all items are accounted for, before discarding any packing material. l,dk WARNING J o If any part is missing or damaged, do not attempt to assemble the miter saw, or plug in the power cord until the missing or damaged part is correctly replaced. Call 1=800-843=1682 for missing or damaged parts. o To avoid electric shock, use only identical replacement parts when servicing double insulated tools. Call 1-800=4-MY=HOME ® for replacement parts. Miter saw Hold-down clamp Dust bag Blade wrench Miter handle Switchhandle Upperbladeguard ON/OFFtrigger switch Bevellockhandle Motor Hold-down clamp Laserguide Tableinsert Miterhandle Mountinghole Turntable LaserON/OFFswitch Hold-down latch Lowerbladeguard Slidecarriage Slidecarriage lockknob Bevelscale Sawblade Handholdfor transportation Positivestoplockinglever Positivemiterdetent Base AMPERAGE (AMPS)- A measure oftheflowofelectriccurrent.Higher ratingsgenerallymeansthetoolis suitedforheavieruse. eyes.Eyeprotection shouldmeetthe requirements ofANSIZ.87.1(USA)or CSAZ94.3-M88 (Canada). ARBORLOCK- Allowstheuserto keepthebladefromrotatingwhile tightening or looseningthearborbolt duringbladereplacement or removal. FACESHIELD- An impactresistant shieldthathelpstoprotectyourface fromchips,sparks,smalldebris. Shouldonlybeusedinconjunction with additional eyeprotection. BASE- Supportsthetable,holds FENCE- Helpsto keeptheworkpiece accessories andallowsforworkbench frommovingwhensawing.Scaledto or legsetmounting. assistwithaccuratecutting. BEVELLOCKINGHANDLE- Locks themitersawat a desiredbevelangle. BEVELSCALE- Tomeasurethe bevelangleofthesawblade0° to45° left. CARBIDETIPPED- Extremely hard steelpieceswithsharpcuttingedges fastenedtocuttingtoolssuchassaw blades. COVERPLATESCREW- Loosenthis screwandrotatetheplateforaccessto thebladearborbolt. GUARD- Protective devisethatforms a barrierbetweena hazardous object suchasa blade,wheelor cutterand theoperator. HOLDDOWNLATCH- Locksthe mitersawintheloweredpositionfor compactstorageandtransportation. INSTRUCTION OROPERATOR'S MANUAL- Bookletaccompanying yourpowertoolthatdescribesthe hazardsandsafeoperation procedures, outlinesbasictooloperation, careand maintenance. DOUBLE-INSULATED - Aformof electricalprotection featuringtwo separateinsulationsystemsto help protectagainstelectricalshock. MITER HANDLE - Used to rotate the table, and to rotate the saw to a right or left cutting position. EXTENSION CORD- MITER SCALE - Measures the miter angle 0 ° to 45 ° left and right. An electric cord used between power tools and outlets to extend the range of the tools. The more amerage your tool uses, the longer the distance, the larger the size of the wire needed in your extension cord. EYE PROTECTION - Goggles or spectacles intended to protect your MOUNTING HOLES - To mount the miter saw to a stable surface. ON/OFF TRIGGER SWITCH - To start the tool, squeeze the trigger. Release the trigger to turn off the miter saw. POSITIVE STOPLOCKING LEVERLocksthemitersawata presetpositive stopforthedesiredmiterangle. SWITCHHANDLE- Theswitch handlecontainsthetriggerswitchand thelaseron/offswitch.Thebladeis loweredintotheworkpiece bypushing downonthehandle.Thesawwill returnto itsuprightpositionwhenthe handleis released. WARNINGLABELS- Readand understand foryourownsafety.Make surealllabelsarepresentonmachine andlegible. WRENCHSTORAGE - Convenient storage to prevent misplacing the blade wrench. WOODWORKING TERMS ARBOR - The shaft on which a blade is mounted. BEVEL CUT - An angle cut made through the face of the workpiece. COMPOUND CUT - An angled cut to both the edge and face of a board, most common use is with crown molding. CROSS CUT - A cut which runs across the board perpendicular to the grain. FREEHAND - Performing a cut without using a fence (guide), hold down or other proper device to prevent the workpiece from twisting during the cutting operation. HEEL - Misalignment of the blade. KERF - The width of a saw cut, determined by the thickness and set of the blade. KICKBACKSudden and unintended movement of the tool or workpiece. It is typically caused by binding or pinching of the workpiece MITER CUT - A miter is a type of joint where the two parts to be joined are cut at an angle, and typically the finished joint forms a 90-degree angle. Also commonly spelled "mitre". REVOLUTIONS PER MINUTE (RPM) - The number of turns completed by a spinning object in one minute. SAW BLADE PATH - The area of the workpiece or table top directly in line with the travel of the blade or the part of the workpiece which will be cut. SET - The distance between two saw blade tips, bent outward in opposite directions to each other. The further apart the tips are, the greater the set. THIN=KERF BLADE - Thinner than normal blades, remove less material, smaller kerfs (between .065 and .070). Blade thinness also may increase the heat generated while cutting. WORKPIECE - The wood being cut. The surfaces of a workpiece are commonly referred to as faces, ends and edges. i,A WARNING To empty the dust bag, squeeze the metal collar and remove from exhaust ] To avoid injury, do not connect this miter saw to the power source until it is completely assembled and adjusted, and you have read and understood this Operator's Manual. port. Open zipper on underside of bag and empty into waste container. NOTE: Check frequently and empty bag before it gets full. iNSTALLING iNSTALLING THE MITER HANDLE (FIG. A) 1. Thread the miter handle (1) into the hole located at the front of the miter table. THE SAFETY HOLD- DOWN CLAMP (FIG. C) 1. Loosen the hex screw (3) using a Phillips screwdriver from the rear side of the saw base. 2. Place the hold-down clamp assembly (1) in one of the mounting holes (2). 3. Tighten the hex screw (3). Fig. A Fig. C iNSTALLING THE DUST BAG (FIG. B) 1. Squeeze the metal collar wings of the dust bag (1). 2. Place the dust bag neck opening around the exhaust port (2), and release the metal collar wings. 3 2C:: J K 1 _Z_\:: \_ SAW BLADE WRENCH (FIG. D) For convenient storage and prevention of loss, there is a slot (1) in the right side of the switch handle (2) for storing the blade wrench (3) when not in use. 2 /, Fig.2 D_I 3 17 UNLOCKING THE SLIDE CARRIAGE (FIG. E) After removing the saw from the carton, loosen the slide carriage lock knob (1). When transporting or storing the miter saw, the slide carriage should always be locked in position. The slide carriage lock knob (1) is located on the right side of the slide carriage. Fig. E Locking When transporting or storing the miter saw, the cutting head should always be locked in the down position. 1. Push the cutting head down to its lowest position. 2. Push the hold-down latch (2) into the locking hole. IMPORTANT: To avoid damage, never carry the miter saw by the switch handle, the cutting arm or the miter handle. Only lift machine by the base hand holds. I,A WARNING] RELEASING CUTTING HEAD (FIG. F) i_l_ WARNING] To avoid injury and damage to the saw, transport or store the miter saw with the cutting head locked in the down position. Never use the hold down latch to hold the cutting head in a down position for cutting operations. Unlocking 1. Push down slightly on the switch handle (1). 2. Pull out the hold-down latch (2). 3. Allow the cutting head to rise to the up position. Fig. F 2 To avoid injury, disconnect the plug from the power source before performing any adjustments or repair. NOTE: Your miter saw was adjusted at the factory. However, during shipment slight misalignment may have occurred. Check the following settings and adjust if necessary prior to using this miter SaW. REMOVING AND iNSTALLING THE TABLE iNSERT (FIG. G) I_ WARNING] To avoid injury: o Always unplug the saw to avoid accidental starting. Remove all small pieces of material from the table cavity before performing any cuts. The table insert may be removed for this purpose, but always reattach the table insert prior to performing a cutting operation. o Do not start the sliding compound miter saw without checking for interference between the blade and table insert. Damage could result to the blade, table insert or turntable if blade strike occurs during the cutting operation. 1. To remove, loosen and remove the six screws (1) on the table inserts (2) with a Phillips screwdriver and remove the insert. 2. To install, reposition the table inserts, install the six screws and tighten. 3. Check for blade clearance by moving the slide carriage through the full motion of the blade in the table slot. Fig. G 2 ® ® Mounting instructions 1. For stationary use, place the saw in the desired location, directly on a workbench where there is room for handling and proper support of the workpiece. The base of the saw has four mounting holes. Bolt the base of the miter saw (1) to the work surface (5), using the fastening method as shown in Fig H. MOUNTING THE MITER SAW (FIG. H, i) [,_ WARNING i handle. Carrying the tool by the power cord could cause damage to the insulation or the wire connections resulting in electric shock or fire. To avoid injury from flying debris, do not allow visitors to stand near the saw during any cutting operation. Support the saw on a level work surface. Always bolt or clamp the saw to its support. Fig. H 1. Hex Miter head saw bolt base 2. To avoid injury form unexpected saw movement: 3. Rubber washer 4. Flat washer o Disconnect the power cord from the outlet, and lock the cutting 5. 6. 7. 8. 9. head in the lower position using the stop latch. o Lock the slide carriage in place by tightening the slide carriage lock knob. o To avoid back injury, lift the saw by using the designated carrying handles located on the top of the machine. When lifting, bend at your knees, not from your back. o Never carry the miter saw by the power cord or by the switch Workbench Flat washer Lockwasher Hex nut Jam nut 3 4 1 --r- " k I NOTE: Mounting hardware is not included with this tool. Bolts, nuts, washers, & screws must be purchased separately. 2. For portable use, place the saw on a 3/4 in. thick piece of plywood. Bolt the base of the plywood usingthemounting holeson thebase.UseC-clampstoclampthis mounting boardto a stablework surfaceattheworksite.(Fig.I) Fig. I Fig. J 3/4 Inch plywood . REMOVING OR INSTALLING BLADE THE 8. Removing Blade (Fig. J, K, L) i,A WARNING] o To avoid injury from an accidental start, make sure the switch is in the OFF position and plug is not connected to the power source outlet. o Only use a 7-1/4 inch diameter blade. o NEVER cut metals or masonry products with this tool. This miter saw is designed for use on wood and wood-like products only. 1. Unplug the saw from the outlet. 2. Raise the miter saw to the upright position. 3. Raise the lower blade guard (1) to the uppermost position. (Fig. J) 4. While holding the lower blade guard, loosen the cover plate screw (2) with a Phillips screwdriver. 5. Rotate the cover plate (3) to expose the arbor bolt. 6. Place the blade end wrench over the arbor bolt. Locate the arbor lock (5) below motor lower cover. (Fig. K) Press the arbor lock, holding it in firmly while turning the blade clockwise. The arbor lock will then engage and lock the arbor. Continue to hold the arbor lock, while turning the wrench clockwise to loosen the arbor bolt. Fig. K 9. Remove the arbor bolt (4), the arbor collar (6), and the blade (7). Do not remove the inner blade collar. (Fig. L) 10. Raise the lower clear plastic blade guard (1) to the upright position (Eig J) to[emovetheb!ade . NOTE:Payattentiontothepieces removed, notingtheirpositionand directiontheyface.Wipetheblade collarscleanofanysawdustbefore installinga newblade. Fig.L 7 \ 6 4 5. Rotate the cover plate (3) back to its original position until the slot in the cover plate engages with the cover plate screw (2). While holding the lower blade guard, tighten the screw with a Phillips screwdriver. (Fig. J) NOTE: The lower blade guard must be raised to the upright position to access the cover plate screw. 6. Lower the blade guard (1) and verify the operation of the guard does not bind or stick (Fig. J). 7. Be sure the arbor lock (5) is released so the blade turns freely by spinning the blade until the arbor lock disengages. INSTALLING BLADE (FIG. J, K, L) [,A WARNING] i_ WARNING] Un-plug the miter saw before changing/installing the blade. 1. Install a 7-1/4 in. blade with a 5/8 in. arbor making sure the rotation arrow on the blade matches the clockwise rotation arrow on the upper guard, and the blade teeth are pointing downward. 2. Place the arbor collar (6) against the blade and on the arbor. Thread the arbor bolt (4) on the arbor, in a counterclockwise direction. (Fig. L) IMPORTANT: Make sure the flats of the blade collars are engaged with the flats on the arbor shaft. Also, the flat-side of the arbor collar must be placed against the blade. 3. Place the blade wrench on the arbor bolt. 4. Press the arbor lock (5), holding it in firmly while turning the blade counterclockwise. When it engages, continue to press the arbor lock in, while tightening the arbor bolt securely. (Fig. K) o To avoid injury, never use the saw without the cover plate secure in place. It keeps the arbor bolt from falling out if it accidentally loosens, and helps prevent the spinning blade from coming off the saw. o Make sure the collars are clean and properly arranged. Lower the blade into the table and check for any contact with the metal base or the turn table. THE LASER GUIDE (FIG. M) 1. To turn laser on, press on/off rocker switch (1) to "ON" position. 2. To turn off laser, press on/off rocker switch to "OFF" position. Fig. M THE LASER BEAM i,_ WARNING occasional readjustments may be necessary. CAUTION=Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. CAUTION=The use of optical instruments with this product will increase eye hazard. Do not attempt to repair or disassemble the laser, if unqualified persons attempt to repair this laser product, serious injury may result. Any repair required on this laser product should be performed by authorized service center personnel. ] For your own safety, never connect the plug to power source outlet until all the adjustment steps are complete and you have read and understood the safety and operational instructions. Your tool is equipped with the Laser Trac ®cutting guide using Class II laser beam. The laser beam will enable you to preview the saw blade path on the stock to be cut before starting the miter saw. This laser guide is powered by the transformed alternating current supply directly through the power lead. The saw must be connected to the power source and the laser on/off switch must be turned on for the laser line to show. BEVEL STOP ADJUSTMENTS (FIG. N, O, P) j,AWARNING ] i WA..I.G1 AVOID DIRECT EYE CONTACT o Laser is radiated when laser guide is turned on. Avoid direct eye contact. Always un=plug the miter saw from power source before making any adjustments. o Laser Warning Label: max output <1 mW DIODE LASER: 630=670nm, Complies with 21CFR 1040.10 and 1040. 11. Class II laser product. To avoid injury from unexpected starting or electrical shock, make sure the trigger is released and remove the power cord from the power source. 900(0 °) Bevel adjustment (Fig. N) 1. Loosen bevel lock handle (1) and tilt the cutting arm completely to the right. Tighten the bevel lock handle. 2. Place a combination square (2) on the miter table with the ruler against the table and the heel of the square against the saw blade. 3. If the blade is not 90 ° (0°) square with the miter table (5), loosen the bevel lock handle (1), tilt the cutting head to the left, loosen the Iocknut (4) on the bevel angle adjustment bolt (3) and use a 10 mm wrench oo NOTSTAR__NTO _A_ MAX OUTPUT • _WRAO_AT*ON 0_OO__AS_R630670._, LASER _ CL_,SS !!LAS_ PROOUCTj NOTE: All the adjustments for the operation of this machine have been completed at the factory. Due to normal wear and use, some 22 to adjust the stop bolt (3) depth in or out to increase or decrease the bevel angle. Tilt the cutting arm to back to the right at 90 ° (0°) bevel and recheck for alignment. Repeat steps 1 through 4 if further adjustment is needed. Tighten bevel lock handle (1) and Iocknut (4) when alignment is achieved. 4. 5. 6. Fig. N 3 \ 4 45 ° Bevel Adjustment (Fig. P) 1. Loosen the bevel lock handle (8) and tilt the cutting head completely to the left. 2. Using a combination square, check to see if the blade angle is 45 ° to the table. 3. If the blade is not at 45 ° to the miter table, tilt the cutting arm to the right, loosen the Iocknut (9) on the bevel angle adjustment bolt (10) and use a 10 mm wrench to adjust the stop bolt (10) depth in or out to increase or decrease the bevel angle. 4. Tilt the cutting arm to the left to 45 ° bevel and recheck for alignment. 5. Repeat steps 1 through 4 until the blade is at 45 ° to the miter table. 6. Tighten bevel lock handle (8) and Iocknut (9) when alignment is achieved. Fig. P 2 5 90 ° Bevel Pointer Adjustment (Fig. O) 1. When the blade is exactly 90 ° (0°) to the table, loosen the bevel indicator screw (6) using a # 2 Phillips screwdriver. 2. Adjust bevel indicator (7) to the "0" mark on the bevel scale and retighten the screw. Fig. 0 \7 MITER ANGLE ADJUSTMENT (FIG. Q) The sliding compound miter saw scale can be easily read, showing miter angles from 0 ° to 45 ° to the left, and 0 ° to 45 ° to the right. The miter saw table has nine of the most common angle setttings with positive stops at 0 °, 15 °, 22.5 °, 31.6 °, and 45 °. These positive stops position the blade at the desired angle quickly and accurately. Follow the process below for quickest and most accurate adjustments. 1. Unlock the miter table by turning the miter handle (1) counterclockwise. 2. Move the turntable while lifting up on the positive stop locking lever (2) to align the indicator (3) to the desired degree measurement. 3. If the desired angle is one of the nine positive stops, release the positive stop locking lever, making sure the lever snaps into position, and then secure by tightening the miter handle. 4. If the miter angle desired is not one of the nine positive stops, simply lock the miter table into desired angle position by turning the miter handle in the clockwise direction. Fig. Q MITER SCALE iNDiCATOR ADJUSTMENT (FIG. Q) 1. Move the table to the 0° positive stop. 2. Loosen the screw (4) that holds the indicator with a Phillips screwdriver. 3. Adjust the indicator (3) to the 0 ° mark and retighten screw. ADJUSTING FENCE SQUARENESS (FIG. R) 1. Lower the cutting arm and lock in position. 2. Using a square (3), lay the heel of the square against the blade and the ruler against the fence (2) as shown. 3. Loosen the two fence locking bolts (1) with a 6mm hex wrench. 4. Adjust the fence 90 ° to the blade and tighten the four fence locking bolts. CAUTION: If the saw has not been used recently, recheck blade squareness to the fence and readjust if needed. 5. After fence has been aligned, using a scrap piece of wood, make a cut at 90 °, then check squareness on the piece. Readjust if necessary. Fig. R ,fy 1 2 _ ,,/_ ¢'_ i "1 SETTING CUTTING DEPTH (FIG. S) The depth of cut can be preset for even and repetitive shallow cuts. 1. Adjust the cutting head down (See CUTTING HEAD section) until the teeth of the blade are at the desired depth. 2. While holding the upper arm in that position, turn the stop knob (1) until it touches the stop plate (2). 3. Recheck the blade depth by moving the cutting head front to back through the full motion of a typical cut along the control arm. Fig. S 2 ADJUSTING CUTTING DEPTH (FIG. S) The maximum depth travel of the cutting head was set at the factory. Check to see that the blade does not extend more than 1/4 in. below the table insert, and does not touch the control arm throat or any part of the base or table, if the maximum depth needs readjusting: 1. Loosen the stop knob (1) while moving the cutting head down until the blade extends just 1/4 in. below the table insert. Adjust the stop knob (1) to touch the stop plate (2). 3. Recheck the blade depth by moving the cutting head front to back through the full motion of a cut along the control arm. If the blade touches the inside of the control arm, readjust the setting. . SAFETY iNSTRUCTiONS SAW OPERATION FOR BASIC BEFORE USING THE MITER SAW i,A WARNING] To avoid mistakes that could cause serious, permanent injury, do not plug the tool in until the following steps are completed: o Completely assemble and adjust the saw, following the instructions. (ASSEMBLY AND ADJUSTMENTS) o Learn the use and function of the ON/OFF switch, upper and lower blade guards, hold down latch, bevel lock handle and cover plate screws. o Review and understand all safety instructions and operating procedures in this Operator's Manual. (SAFETY & OPERATIONS) o Review the MAINTENANCE and TROUBLESHOOTING GUIDE for your miter saw. o To avoid injury or possible death from electrical shock: Make sure your fingers do not touch the plug's metal prongs when plugging or unplugging your miter saw. (ELECTRICAL REQUIREMENTS AND SAFETY) BEFORE EACH USE iNSPECT YOUR SAW. o Disconnect the miter saw. To avoid injury from accidental starting, unplug the saw before any adjustments, including set-up and blade changes. o Compare the direction of rotation arrow on the guard to the direction arrow on the blade. The blade teeth should always point downward at the front of the saw. o Tighten the arbor bolt. o Tighten the cover plate screw. o Check for damaged parts. Check for: o Alignment of moving parts o Damaged electric cords o Binding of moving parts o Mounting holes o Function of arm return spring and lower guard: Push the cutting arm all the way down, then let it rise until it stops. The lower guard should fully close. Follow instructions in TROUBLESHOOTING GUIDE for adjustment if necessary. o Other conditions that may affect the way the miter saw works. o Keep all guards in place, in working order and proper adjustment. If any part of this miter saw is missing, bent, damaged or broken in any way, or any electrical parts do not work, turn the saw off and unplug it. o Replace bent, damaged, missing or defective parts before using the saw again. o Maintain tools with care. Keep the miter saw clean for best and safest performance. Follow instructions for lubricating. Do not put lubricants on the blade while it is spinning. o Remove adjusting wrench from the tool before turning it on. o To avoid injury from jams, slips, or thrown pieces, use only recommended accessories. RECOMMENDED ACCESSORIES o Consult the ACCESSORIES and ATTACHMENTS section of this Operators Manual for recommended accessories. Follow the instructions that come with the accessory. The use of improper accessories may cause risk of injury to persons. • Choose the correct 7-1/4 in. diameterbladeforthematerialand thetypeofcuttingyouplantodo.Do notusethinkerfblades. o Makesurethebladeis sharp, undamaged andproperlyaligned. Withthesawunplugged, push thecuttingarmallthewaydown. Manuallyspinthebladeandcheck forclearance. Tiltthepower-head to a 45° bevelandrepeatthetest. o Makesurethebladeandarbor collarsareclean. o Makesureallclampsandlocksare tightandthereis noexcessiveplay inanyparts. S FOR SAFETY Any power tool can throw foreign objects into the eyes. This can result in permanent eye damage. Everyday eyeglasses have only impact resistant lenses and are not safety glasses. Glasses or goggles not in compliance with ANSI Z87.1 could seriously injure you when they break. o Do not wear loose clothing, gloves, neckties or jewelry (rings, watches). They can get caught and draw you into moving parts. o Wear non-slip footwear. o Tie back long hair. o Roll long sleeves above the elbow. o Noise levels vary widely. To avoid possible hearing damage, wear ear plugs when using any miter saw. o For dusty operations, wear a dust mask along with safety goggles. KEEPYOUR WORK AREA CLEAN Cluttered areas and benches invite accidents. ,_k WARNING in a solidly braced, fixed position. CAUTION: This machine is not designed for cutting masonry, masonry products, ferrous metals (steel, iron, and iron-based metals.) Use this miter saw to cut only wood, wood-like products, or nonferrous metals. Other material may shatter, bind the blade, or create other dangers. Remove all nails that may be in the workpiece to prevent sparking that could cause a fire. Remove dust bag when cutting nonferrous metals. I To avoid burns or other fire damage, never use the miter saw near flammable liquids, vapors, or gases. o Plan ahead to protect your eyes, hands, face and ears. o Know your miter saw. Read and understand the Operator's Manual and labels affixed to the tool. Learn its application and limitations as well as the specific potential hazards peculiar to this tool. To avoid injury from accidental contact with moving parts, do not do layout, assembly, or setup work on the miter saw while any parts are moving. o Avoid accidental starting, make sure the trigger switch is disengaged before plugging the miter saw into a power outlet. INSPECT YOUR WORKPIECE Make sure there are no nails or foreign objects in the part of the workpiece being cut. Plan your work to avoid small pieces that may bind, or that are too small to clamp and get a solid grasp on. Plan the way you will grasp the workpiece from start to finish. Avoid awkward operations and hand positions. PLAN YOUR WORK o Use the right tool. Do not force a tool or attachment to do a job it was not designed to do. Use a different tool for any workpiece that can't be held 27 A sudden slip could cause your fingers or hand to move into the blade. DO NOT OVER-REACH Keep good footing and balance. Keep your face and body to one side, out of the line of a possible kickback. NEVER stand in the line of the blade. Never cut freehand: o Brace your workpiece firmly against the fence and table stop so it will not rock or twist during the cut. o Make sure there is no debris between the workpiece and the table or fence. o Make sure there are no gaps between the workpiece, fence and table that will let the workpiece shift after it is cut. o Keep the cut off piece free to move sideways after it is cut off. Otherwise, it could get wedged against the blade and thrown violently. • Only the workpiece should be on the saws table. o Secure work. Use clamps or a vise to help hold the work when it is practical. "no hands zone" area marked on the saws table. o When cutting odd shaped workpieces, plan your work so it will not bind in the blade and cause possible injury. Molding, for example, must lie flat or be held by a fixture or jig that will not let it move when cut. o Properly support round material such as dowel rods, or tubing, which have a tendency to roll when cut, causing the blade to "bite". l_, WARNING i To avoid injury, follow all applicable safety instructions, when cutting non-ferrous metals: o Use only saw blades specifically recommended for non-ferrous metal cutting. o Do not cut metal workpieces that must be hand held. Clamp workpieces securely. o Cut non-ferrous metals only if you are under the supervision of an experienced person and the dust bag has been removed from the saw. USE EXTRA CAUTION WITH LARGE OR ODD SHAPED WORKPIECES. o Use extra supports (tables, sawhorses, blocks, etc.) for workpieces large enough to tip. o Never use another person as a substitute for a table extension, or as an additional support for a workpiece that is longer or wider than the basic miter saw table, or to help feed, support, or pull the workpiece. o Do not use this saw to cut small pieces. If the workpiece being cut would cause your hand or fingers to be within 6-3/4 inches of the saw blade the workpiece is too small. Keep hands and fingers out of the WHEN SAW IS RUNNING I,_ WARNING] Do not allow familiarity from frequent use of your miter saw to result in a careless mistake. A careless fraction of a second is enough to cause a severe injury. Before cutting, if the saw makes an unfamiliar noise or vibrates, stop immediately. Turn the saw OFF. Unplug the saw. Do not restart until finding and correcting the problem. BODYAND [_ HAND POSITION (FIG. T) Fig. T WARNING] the cutting Never placearea. handsProper near positioning of your body and hands when operating the miter saw will make cutting easier and safer. Keep children away. Keep all visitors at a safe distance from the miter saw. Make sure bystanders are clear of the saw and workpiece. Do not force the saw. it will do the job better and safer at its designed rate. _-- _ No Hand Zone 13-1/2 in. BASIC SAW OPERATIONS Starting a cut: o Place hands at least 6-3/4 in. away on both sides of the blade path - "nohands zone". (Fig. T) o Hold workpiece firmly against the fence to prevent movement toward the blade. o With the power switch OFF, bring the saw blade down to the workpiece to see the cutting path of the blade. o Squeeze trigger switch to start saw. o Lower blade into workpiece with a firm downward motion. Finishing a cut: e Hold the cutting arm in the down position. o Release trigger switch and wait for all moving parts to stop before moving your hands and raising the cutting arm. o If the blade does not stop within 10 seconds, unplug the saw and follow the instructions in TROUBLESHOOTING GUIDE section. Before freeing jammed material: o Release trigger switch. o Wait for all moving parts to stop. o Unplug the miter saw. [_, WARNING] For your convenience, your saw has a blade brake. The brake is not a safety device. Never rely on it to replace the proper use of the guard on your saw. If the blade does not stop within approximately 10 seconds, wait for the blade to stop, unplug the saw and check the Troubleshooting Guide on page 39. Contact customer service at 1-800=843=1682 for additional technical information is needed. TO TURN THE SAW ON (FIG. U) Depress the trigger switch (1) to turn on the miter saw started. The miter saw is equipped with an automatic blade brake. When the trigger switch is released, the electric blade brake will stop the blade within approximately 10 seconds. NOTE: Make the ON/OFF switch childproof. Insert a padlock, or chain with padlock, through the hole (2) in the trigger switch, locking the tool's switch, preventing children and other unauthorized users from turning the machine on. Fig. U I WARNINGi To avoid injury from materials being thrown, always unplug the saw to avoid accidental starting, and remove small pieces of material from the table cavity. SLiDiNG CARRIAGE SYSTEM (FIG. V) [_1_ WARNING] To reduce the risk of injury, return carriage to the full rear position after each crosscut operation. 1. For a chop cutting operations on small workpieces, slide the cutting head assembly completely toward the rear of the unit and tighten the carriage lock knob (1). 2. To cut wide boards up to 8 in., the carriage lock knob should be loosened to allow the cutting head to slide freely. Fig. V MITER CUT (FIG. W) 1. When a miter cut is required, unlock the miter table by turning the miter handle (1) counterclockwise. 2. While holding the miter handle, lift up on the positive stop locking lever (2). 3. Rotate the miter table to the right or left with the miter handle. 4. When the table is in the desired position, as shown on the miter scale (3), release the positive stop locking lever and tighten the miter handle. The table is now locked at the desired angle. Positive stops are provided at 0°, 15 °, 22.5 °, 31.6 ° and 45 ° . iMPORTANT: Always tighten the miter table lock handle before performing every cutting operation. Fig. W BEVEL CUT (FIG. X) 1. When a bevel cut is required, loosen the bevel lock handle (1) by turning it clockwise. 2. Tilt the cutting head to the desired angle, as shown on the bevel scale (2). 3. The blade can be positioned at any angle, from a 90 ° straight cut ( 0 ° on the scale) to a 45 ° left bevel. Tighten the bevel lock handle (1) to lock the cutting head in position. Positive stops are provided at 0 ° and 45 °. Fig. Y \ Fig. X SLIDE CUTTING WIDE BOARDS UP TO 8 in. WIDE (FIG. Z) [,_ 2 COMPOUND CUT (FIG. Y) A compound cut is the combination of a miter and a bevel cut simultaneously. 1. Loosen the bevel lock handle (1) and position the cutting head at the desired bevel position. Lock the bevel lock handle. 2. Loosen the miter handle (2). Lift up the positive stop locking lever and position the table at the desired angle. Release the positive stop locking lever and lock the miter handle. WARNING] To avoid injury: o Never pull the cutting head assembly and spinning blade toward you during the cut. The blade may try to climb up on the top of the workpiece, causing the cutting assembly and spinning blade to kick back forcefully. The cutting head assembly should be drawn back completely then pushed forward when sawing. o Let the blade reach full speed before cutting. This will help reduce the risk of a thrown workpiece. ToSlideCutWide Boards (Fig. Z) 1. Unlock the carriage lock handle (1) and allow the cutting head assembly to move freely. 2. Set both the desired bevel angle and/or the miter angle and lock into position. 3. Use a hold down clamp to secure the workpiece. 4. Grasp and pull forward the switch handle (2) until the center of the saw blade is over the front of the workpiece (3). 5. Engage the trigger to turn the saw CUTTING BOWED MATERIAL (FIG. AA) i_ 7. 8. 1 To avoid injury from materials being thrown, always unplug the saw to avoid accidental starting and remove small pieces of material from the table cavity. The table insert may be removed for this purpose, but always reattach table insert prior to performing a cutting operation. on. 6. WARNING A bowed workpiece must be positioned against the fence and secured with a clamping device as shown before cutting. Do not position workpiece incorrectly or try to cut the workpiece without the support of the fence. This will cause the blade to bind and could When the saw reaches full speed, push the switch handle down, slowly, cutting through the leading edge of the workpiece. Slowly move the switch handle toward the fence, completing the cut. Release the trigger and allow the blade to stop spinning before allowing the cutting head to raise. result in personal injury. Fig. AA Fig. Z 2 3 ROUGH CUTTING A DADO (FIG. BB) i,_ WARNING} DO NOT USE A DADO BLADE, use only the standard saw blade for this operation. 1. Mark lines identifying the width and depth of the desired cut on 32 theworkpiece andpositiononthe tablesotheinsidetip oftheblade is positioned onthe line.Usea holddownclamptosecurethe workpiece. 2. Lowerthecuttingheadsothetip of thebladetouchesthetopsurface workpiece atthemarkedline. 3. Whileholdingtheupperarmin position, turnthestopknob(2)until ittouchesthestopplate(1). 4. Cuttwoparallelgroovesasshown below. Fig. BB 2 Cut these grooves with saw Use a chisel to cut out the middle Fig. CO 3-1/4 in. AUXILIARY WOOD FENCE (FIG. DD) When making multiple or repetitive cuts that result in cut-off pieces of one inch or less, it is possible for the saw blade to catch the cut-off piece and throw it out of the saw or into the blade guard and housing, possibly causing damage or injury. To minimize this an auxiliary wood fence can be mounted to your saw. Holes are provided in the saw fence to attach an auxiliary wood fence (this provides additional depth of cut). This fence should be constructed of straight auxiliary wood approximately 3/4 in. thick by 1-1/2 in. high by 16 in. long. Attach the wood fence securely and make a full depth cut to make a blade slot. Check for interference between the wood fence and the lower blade guard. Adjust if necessary. Fig. DD WORKPIECE SUPPORT (FIG. CO) Long pieces need extra support. The support should be placed under the workpiece. Keep your hand holding the workpiece positioned 6-3/4 inches or more away from the blade. The support must let the workpiece lay flat on the work table during the cutting operation. NOTE: When mounted on a flat surface, the saw table is 3-1/4 inches high. / Auxiliary fence \ Blade slot CUTTINGBASEMOLDING (FIG. EE) Base moldings and many other moldings can be cut on a compound miter saw. The setup of the saw depends on molding characteristics and application, as shown. Perform practice cuts on scrap material to achieve best results: 1. Always make sure moldings rest firmly against fence and table. Use hold-down, crown molding vise or C-clamps, whenever possible, and place tape on the area being clamped to avoid marks. 2. Reduce splintering by taping the cut area prior to making the cut. Mark the cut line directly on the tape. 3. Splintering typically happens due to an incorrect blade application and thinness of the material. angles that, when added to_ equal exactly 90 °. Most crown molding has a top rear angle (the section that fits flat against the ceiling) of 52°and a bottom rear angle (the section that fits flat against the wall) of 38 ° . In order to accurately cut crown molding for a 90 ° inside or outside corner, lay the molding with its broad back surface flat on the saw table. When setting the bevel and miter angles for compound miters, remember that the settings are interdependent; changing one changes the other, as well. Fig. FF e Fig. EE Miter saw table Bevel/Miter Miter saw table miter at 450, bevel at 0° miter at 0°, bevel at 450 NOTE: Always 3erform a dry run cut so you can determine if the operation being attempted is possible before power is applied to the saw. CUTTING CROWN MOLDING (FIG. FF, GG) [,d_ WARNING] Your compound miter saw is suited for the difficult task of cutting crown molding. To fit properly, crown molding must be compound-mitered with extreme accuracy. The two surfaces on a piece of crown molding that fit Settings Fig. GG Settings for standard crown molding lying flat on compound miter saw table ] Inside corner OR \ I[ Outside corner Compound cut crown moldings NOTE: The chart below references a compound cut for crown molding ONLY WHEN THE ANGLE BETWEEN Bevel/MiterSettings KEY BEVEL SETTING MITER SETTING TYPE OF CUT inside corner-Left side IL 33.9 ° 31.6 o Right il. Position top of molding against fence. i2. Miter table set at RIGHT 31.6 °. 3. LEFT side is finished piece. IR 33.9 ° 31.6 ° Left inside corner-Right side il. Position bottom of molding against fence. i2. Miter table set at LEFT 31.6 °. 3. LEFT side is finished piece. Outside corner-Left side OL OR 33.9 ° 33.9 ° 31.6 ° Left il. Position bottom of molding against fence. i2. Miter table set at LEFT 31.6 °. i3. RIGHT side is finished piece. Outside corner-Right side 31.6 o Right il. Position top of molding against fence. 2. Miter table set at RIGHT 31.6 ° . 3. RIGHT side is finished piece. CROWNMOLDING CHART Compound Miter saw Miter and bevel Angle settings Wall to Crown Molding Angle 52/38 ° C_wn Molding 45/45 ° C_wn Molding 52/38 ° Crown Molding 45/45 ° Crown Molding Angle Miter Bevel Miter Bevel Angle Miter Bevel Miter Bevel Between Walls Setting Setting Se_ing Setting Between Wails Setting Setting Setting Setting 67 42.93 41.08 46.89 36.13 124 18.13 21.71 20.61 19.39 68 69 42.39 41.88 40.79 40.50 46.35 45.81 35.89 35.64 128 126 17.77 17.42 21.34 20.96 20.21 19.81 19.06 18.72 70 41.32 40.20 45.28 35.40 127 17.06 20.89 19.42 18.39 71 40.79 39.90 44.75 35.15 128 16.71 20.21 19.03 18.06 72 40.28 39.61 44.22 34.89 129 16.37 19.83 18.64 17.72 73 39.76 39.30 43.70 34.64 130 16.02 19.48 18.28 17.39 74 39.28 39.00 43.18 35.38 131 18.67 19.07 17.86 17.05 75 38.74 38.69 42.66 34.12 132 18.33 18.69 17.48 16.71 76 38.24 38.39 42.15 33.86 133 14.99 18.31 17.09 16.38 77 37.74 38.08 41.64 33.60 134 14.66 17.93 16.71 16.04 78 37.24 37.76 41.13 33.33 138 14.30 17.88 16.32 18.70 79 36.78 37.45 40.62 33.07 136 13.97 17.17 18.94 18.36 80 81 36.27 35.79 37.13 36.81 40.12 39.62 32.80 32.53 137 138 13.63 13.30 16.79 16.40 18.86 18.19 18.02 14.62 82 35.31 36.49 39.13 32.25 139 12.96 16.02 14.81 14.34 83 84 34.83 34.36 36.17 35.85 38.63 38.14 31.98 31.70 140 141 12.63 12.30 18.64 18.28 14.43 14.06 14.00 13.65 85 33.90 35.52 37.66 31.42 142 11.97 14.87 13.68 13.31 86 33.43 35.19 37.17 31.34 143 11.64 14.48 13.31 12.97 87 32.97 34.86 36.69 30.86 144 11.31 14.09 12.94 12.62 88 32.52 34.53 36.21 30.57 148 10.99 13.71 12.87 12.29 89 32.07 34.20 35.74 30.29 146 10.66 13.32 12.20 11.93 90 31.62 33.86 35.26 30.00 147 10.34 12.93 11.83 11.59 91 31.17 33.53 34.79 29.71 148 10.01 12.84 11.46 11.24 92 30.73 33.19 34.33 29.42 149 9.69 12.16 11.09 10.89 93 30.30 32.86 33.86 29.13 180 9.37 11.77 10.73 10.55 94 29.86 32.51 33.40 28.83 181 9.08 11.38 10.36 10.20 95 29.43 32.17 32.94 28.54 182 8.73 10.99 10.00 9.85 96 97 29.00 28.58 31.82 31.48 32.48 32.02 28.24 27.94 183 184 8.41 8.09 10.60 10.21 9.63 9.27 9.80 9.15 98 28.16 31.13 31.58 27.64 188 7.77 9.82 8.91 8.80 99 100 27.74 27.32 30.78 30.43 31.13 30.68 27.34 27.03 186 187 7.46 7.14 9.43 9.04 8.88 8.19 8.45 8.10 101 26.91 30.08 30.24 26.73 188 6.82 8.68 7.83 7.75 102 26.50 29.73 29.80 26.42 189 6.81 8.26 7.47 7.40 103 26.09 29.38 29.36 26.12 160 6.20 7.86 7.11 7.05 104 25.69 29.02 28.92 25.81 161 8.88 7.47 6.78 6.70 105 25.29 28.67 28.48 25.50 162 8.87 7.08 6.39 6.35 106 24.89 28.31 28.05 25.19 163 8.26 6.69 6.03 6.00 107 24.49 27.96 27.62 24.87 164 4.98 6.30 8.68 8.65 108 24.10 27.59 27.19 24.56 168 4.63 5.90 8.32 8.30 109 23.71 27.23 26.77 24.24 166 4.32 5.81 4.96 4.94 110 23.32 26.87 26.34 23.93 167 4.01 8.12 4.61 4.89 111 22.93 26.51 25.92 23.61 168 3.70 4.72 4.28 4.24 112 22.58 26.15 25.50 23.29 169 3.39 4.33 3.90 3.89 113 22.17 25.78 25.08 22.97 170 3.08 3.94 3.84 3.53 114 115 21.79 21.42 25.42 25.05 24.66 24.25 22.66 22.33 171 172 2.77 2.47 3.84 3.18 3.19 2.83 3.10 2.83 116 21.04 24.68 23.84 22.01 173 2.18 2.78 2.48 2.47 117 20.67 24.31 23.43 21.68 174 1.88 2.36 2.12 2.12 118 20.30 23.94 23.02 21.36 178 1.84 1.97 1.77 1.77 119 19.93 23.57 22.61 21.03 176 1.23 1.88 1.41 1.41 120 19.57 23.20 22.21 20.70 177 0.92 1.18 1.06 1.06 121 19.20 22.83 21.80 20.38 178 0.62 0.79 0.71 0.71 122 18.84 22.46 21.40 20.08 179 0.31 0.39 0.38 0.35 123 18.48 22.09 21.00 19.72 MAINTENANCE I_ DANGER NOTE: To reinstall the same brushes, first make sure the brushes go back in the way they came out. This will avoid a break-in period that reduces motor performance and increases wear. i To avoid injury, never put lubricants on the blade while it is spinning. [,A WARNING] o To avoid fire or toxic reaction, never use gasoline, naphtha acetone, lacquer thinner or similar highly volatile solvents to clean the miter saw. o To avoid injury from unexpected starting or electrical shock, unplug the power cord before working on the saw. For your safety, this saw is double=insulated. To avoid o Fig. HH 2 LOWER BLADE GUARD Do not use the saw without the lower electrical shock, fire or injury, use only parts identical to those identified in the parts list. Reassemble exactly as the original assembly to avoid electrical shock. blade guard. The lower blade guard is attached to the saw for your protection. Should the lower guard become damaged, do not use the saw until the damaged guard has been replaced. Develop a regular check to make sure the lower guard is working properly. Clean the lower guard of any dust or buildup with a damp cloth. REPLACING CARBON BRUSHES (FIG. HH) Replace both carbon brushes when either has less than 1/4 in. length of carbon remaining, or if the spring or wire is damaged or burned. To inspect or replace brushes, first unplug the saw. Then remove the black plastic cap (1) on the side of the motor (2). Remove the cap cautiously, because it is springloaded. Then pull out the brush and replace. Replace for the other side. To reassemble reverse the procedure. The of the assembly the carbon part cap snugly, but l,_ o o WARNING i When cleaning the lower guard, unplug the saw from the power source receptacle to avoid unexpected startup. Do not use solvents on the guard. They could make the plastic "cloudy" and brittle. ears on the metal end go in the same hole fits into. Tighten the do not overtighten. 37 SAWDUST Periodically, sawdust will accumulate under the work table and base. This could cause difficulty in the movement of the worktable when setting up a miter cut. Frequently blow out or vacuum up the sawdust. i,A WARNING Fig. II 1 Wear proper eye protection to keep debris from entering eyes when removing sawdust from unit. Chop pivot Fig. JJ LUBRICATION (FIG. II, JJ) All the motor bearings in this tool are lubricated with a sufficient amount of high grade lubricant for the life of the unit under normal operating conditions; therefore, no further lubrication is required. Lubricate the Following as necessary: Chop pivot: Apply light machine oil to points indicated in illustration. Central pivot of plastic guard: Use light household oil (sewing machine oil ) on metal-to-metal or metal-toplastic guard contact areas as required for smooth, quiet operation. Avoid excessive oil, to which sawdust will cling. Link: (actuates lower guard movement) If down chop motion is hard to start, oil link at two screws (1). Central pivot of plastic guard i,A WARNING ] To avoid injury from accidental starting, always turn switch OFF and unplug the tool before moving, replacing the blade or making adjustments. TROUBLESHOOTING PROBLEM Brake does GUIDE = MOTOR PROBLEM CAUSE 1. Motor brushes not sealed notstop blade or lightly sticking. within 10 2. Motor brake overheated seconds. from use of defective or wrong size blade or rapid ON/OFF cycling. 3. Arbor bolt loose. 4. Brushes cracked, damaged, etc. 5. Other. SUGGESTED CORRECTIVE ACTION 1. Inspect/clean/replace brushes. See MAINTENANCE section. 2. Use a recommended blade. Let cool down. See REMOVING OR INSTALLING THE BLADE section. 3. Retighten. See REMOVING OR INSTALLING THE BLADE section. 4. Replace brushes. 5. Contact Sears Service Center. Motor does not start 1. Limit switch failure 2. Brush worn. 3. Fuse blown or circuit breaker tripped on home panel. . Replace limit switch. 2. Replace brushes. See MAINTENANCE section. 3. Verify there is electrical power at the outlet. Brush spark when switch released. 1. Brush worn. 2. Other. 1. Replace Brushes. See MAINTENANCE section. 2. Contact Sears Service Center. TROUBLESHOOTING PROBLEM GUIDE =SAW OPERATION PROBLEM CAUSE SUGGESTED CORRECTIVE ACTION Blade hits table. 1. Misalignment. Angle of cut not accurate. Can not adjust miter. 1. Miter table unlocked. 2. Sawdust under table. 1. See ADJUSTMENT -Setting Cutting Depth section. 1. See OPERATION - Miter Angle Adjustment section. 2. Vacuum or blow out dust. WEAR EYE PROTECTION. Cutting arm wobbles. 1. Loose pivot points. 1. Contact Sears Service Center. Cutting arm will not fully raise, or blade guard won't fully close. Blade binds, ams, burns wood. 1. Pivot spring not replaced 1. Contact Sears Service Center. properly after service. 2. Clean and lubricate moving 2. Sawdust build-up, parts. 1. 2. 3. 4 Improper operation. Dull or warped blade. Improper blade size. Wood is moving during cut. Saw vibrates or 1. Saw blade not round/ shakes, damaged /loose. 2. Arbor bolt loose. 1. See BASIC SAW OPERATION section. 2. Replace or sharpen blade. 3. Replace with 7-1/4 in. diameter blade. 4. Use hold down clamp to secure workpiece to table. 1. Replace blade. 2. Tighten arbor bolt. 74/4 in. COMPOUND [_ MITER SAW MODEL NO. 137.211940 WARNING] When servicing use only CRAFTSMAN replacement parts. Use of any other parts many create a HAZARD or cause product damage. Any attempt to repair or replace electrical parts on this Miter Saw may create a HAZARD unless repair is done by a qualified service technician. Repair service is available at your nearest Sears Service Center. PARTS LiST FOR SAW SCHEMATIC I,D, 083S Description TRIGGER 083Z CORD Size Qty I.D. 290M Description CAUTION LABEL 27PF COMPRESSION 091S COMPRESSION 0B5N COMPRESSION SPRING 2BB6 FENCE SPRING 2BGV NEEDLE POINTER 0CES COMPRESSION 0CF5 0CV5 SHAFT PIVOT DUST BAG ASSAY SPRING 2BGW SLIDE PLATE 2BLG 2BLL SHAFT PIVOT LOCATOR PIN 0DHT 0DHY 0DVJ SPRING GUARD 2CA8 CR ARBOR COLLAR 2CD2 COMPRESSION BLADE WRENCH 2CGT SLOTrED 0HXV LINEAR MOTION @6_13 1 2CHF 2DAT PLUNGER HOUSING SCALE 0J4E FLAT WASHER 0J4F FLAT WASHER 0J4J 0J4L FLAT WASHER FLAT WASHER @8_16 25 2E63 ROCKER SWITCH @1020 @122] 2KEQ WARNING 0J7K 0JBO FLAT WASHER WAVE WASHER 3/8"27/32 2K96 2NO6 WARNING RIVET 2QBG CLAMP 0JBB WAVE 0JE6 C RING 2RSC 0JET E RING 2RSB 2RSD ARM #AW BASE #AW TABLE 0JMM 0JNR O RING O RING 2RSF 2RSG ARM MITER PLUNGER HANDLE #AW 0JPE HEX HD BOLT M6*I 0 20 2RSH LOCKING 0JPF HEX HD BOLT M6*] 0 25 2RSJ PC GUARD 0JQ3 HEX HD BOLT M10_1 5 65 2RSL CUTTER SHAFT GUARD 0JV6 0JX7 HEX SOC HEX SOO M10"1 5 25 M6*I 0 B 2RSM TABLE INSERT {RIGHT) 0JZN ARBOR BOLT 2RSN 2RSP TABLE INSERT {LEFT) BRACING PLATE 0K5D CR RE COUNT 0K7X 0KA9 CR CR RE TRUSS HD ROUND RE PAN HE)TAPPING NECK SCREW SCREW M6*I 0 10 M3"24 ]0 2RSQ 2RSR 2RSS MOTOR HANDLE MOTOR HANDLE CLEVIS PIN 0KB7 CR RE PAN HD TAPPING SCREW M418 ]6 2RST CENTER SHAFT 0KBA CR RE PAN HD TAPPING SCREW M516 ]2 2RSU COVER 0KBC CR RE PAN HE)TAPPING SCREW M516 25 2RWY VISE ASS'Y 0KBM CR RE PAN HD TAPPING SCREW M4"]8 28 2RXl LEVER 0KD5 0KD6 CR CR RE PAN HE) SCREW RE PAN HD SCREW M407 M4"07 6 8 2RX3 2RX4 LASER PLUNGER COVER 0KD7 CR RE PAN HD SCREW M407 10 2RX5 TILT POINTER 0KDH CR RE PAN HE) SCREW M508 8 2S1E BLADE 0KDQ CR RE PAN HD M508 35 284L BEARING COVER 0KDT 0KDW CR CR RE PAN HD SCREW RE PAN HE) SCREW M6*] 0 8 M6*] 0 20 2S52 2S62 MOTOR ASS'Y MITER BAR ASSY 0KKK CR RE PAN HD 2S65 POWER CABLE 0KMS HEX NUT M6IOT 0KQW LOCK NUT M508 0KQY 0KQX LOCK NUT NUT MEI 25 T 8 M6*I 0T 6 0KRO NUT 0KR3 LOCK 0KTQ CABLE CLAMP 0KTS 0KUW 0LU2 CLAMP BEARING 2 25 5/64 WASHER ROD HD CAP BOLT SET SCREW ME1 25 20 HD SCREW M6*I SCREW ROUND NECK SCREW 0 20 M6*] 0 12 Size #AW RE TRUSS HD ROUND M6*I LABEL BOLT #AW HANDLE ASSY {TOP} {DOWN) HOUSING 2SER HOLD DOWN 2TBA 2T82 CONTROLLER ASS 'Y SHAFT SLEEVE 2T83 TORSION 2TgK OPERATORS 2TgN LABEL CABLE CLAMP TERMINAL 2TgP 2T9© CAUTION LABEL TRADE MARK LABEL LIMIT SWITCH 2TgR WARNING 0SIS COLLAR 2T9S TRADE 23NX GUARD 2TgT TILTING SCALE 262V 26LU ANCHOR WARNING 2T9U 2TgV BRACKET TILT CAUTION LABEL 27KY CLAMP 2TGY CR 175T CORD PLATE LABEL BOLT 12 6 0 8 LABEL T 5 M610T M6"1 0 12 ASSY 2S67 M12 NECK SCREW SPRING SETSCREW 5 NUT Qty SPRING LEAD WIRE ASS'Y CLAMP ASS'Y SPRING MANUAL LABEL MARK LABEL RE PAN HD SCREW & WASHER M6*] 0 80 7=1/4 in. COMPOUND MITER SAW MODEL NO. 137.211940 SCHEMATIC OKBA OKTS OKTQ\ 0C_'5 OJBO i i i 2TgR _2CD2 2RSH / 7=1/4 in. COMPOUND MITER SAW MODEL NO. 137.211940 PARTS LiST FOR MOTOR Size I.D. Description 0HX7 NEEDLE ROLLER BEARING 0iX2 HEX. SOC. SETSCREW M5_0.8-6 2 0KC© CR. RE. PAN HEAD TAPPING & WASHER SCREW M5 _ 12-65 2 0KNE HEX. NUT M6"1.0 T=5 2 0©BE BRUSH HOLDER ASS'Y 2 0©BG CARBON 2 0©BK BRUSH COVER 2 2BMS CUTTER SHAFT 1 2BMT SPACER 1 2BMU HELIX GEAR 1 2BMX FLOW GUIDE 1 2BN1 MOTOR COVER 1 2DW9 WAVE WASHER 1 2EOJ BALL BEARING 1 2S3B GEAR BOX 1 2S6R FIELD ASS'Y 1 2S6T ARMATURE ASS'Y 1 1 BRUSH ASS'Y @ 2S6R_ 2DW9 OKNE2_ 2S3B_ 2B OH "_ Q'l'y Your Home For expert troubleshooting and home solutions advice: manage www.managernyhorne.com For repair - in your home - of all major brand appliances, lawn and garden equipment, or heating and cooling systems, no matter who made it, no matter who sold it! For the replacement parts, accessories and owner's manuals that you need to do-it-yourself. For Sears professional installation of home appliances and items like garage door openers and water heaters. 1-800-4-MY-HOME Call anytime, ® (1-800-4694663) day or night (U.S.A. and Canada) www.sears.comwww.sear_.c_ oct Home Forrepair ofcarry-in items likevacuums, lawn equipment, and electronics, call anytime for the location of your nearest SearsPaas&Repair Se_iceCenter 1-800-488-1222 (U.S.A.) 1-800-469-4663 www.sears.com 11iii/To purchase www.sears.ca (U.S.A.) 1"800-361-6665 Para pedir se_vicio de,epa_aci6n (1-888-784-6427) MC Marque Trademark Registrada / TM de commerce / TM Trademark Marca / MD / de Fabdca Marque SM / de Sears 1-800-LE-FOYER _'° (1-800-533-6937) _ www.sears.ca Service Mark of Sears Brands, sM Marca de Servicio de Sears deposse Brands, (Canada) AuCanada pou,service enfran_ais: a domicilio,y para ordenar piezas: 1-888-SU-HOGAR ® ® Marca 1i a protection agreement on a product serviced by Sears: 1"800-827"8655 _) Registered (Canada) LLC LLC Brands, LLC ©Sears Brands, LLC
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